Product 

Specification 03433 
(Revision NEW, 3/2015) 

Flex500 
Digital Control for Turbines, Engines, or Compressors   Powerful real-time
microprocessor
control for
Applications  turbines &
engines
The Flex500 control system represents a new
generation of turbine and engine control. This  Optional
controller is an industrial hardware platform that integrated
offers robust, low-cost control for a wide variety of
graphical operator
turbine, engine, and compressor applications. The
platform’s real-time operating system and control panel
dedicated inputs and outputs provide deterministic
 Fast, accurate
performance for key prime-mover-control
functionality.
on-board I/O
channels
Designed to function as a distributed control
system, Woodward-based RTCnet™ and/or  Combines real
LINKnet HT™ distributed I/O modules can be time control with
used in conjunction with this platform to expand PLC programming
the number and type of input and output signals as
required by the specific application.  Deterministic
Ethernet, serial and CAN communication ports, scan rates as fast
and the related Modbus® * TCP/IP and CANopen as 5 ms
protocols also make this platform ideal for functioning as part of an overall plant
distributed control system (DCS) or as a standalone controller. Four Ethernet ports  Distributed I/O
and four CAN ports allow for the network flexibility and redundancy necessary for capability
today’s critical control system architectures. The Flex500 controller is a custom-
programmed hardware platform designed specifically for prime-mover-control  Compliant with
applications such as: time
 Gas turbines synchronization
 Compressor control and protection protocol SNTP
 Gas and diesel engines
 Steam turbines  Networked
 Hydro turbines control
All controller inputs, outputs, and statuses can be monitored, and all start/stop or  4 Ethernet ports
enable/disable commands can be given, through industry-standard Modbus TCP or
OPC protocols. The Flex500 platform uses SNTP (synchronized network time  4 CANopen ports
protocol) over Ethernet to allow users to synchronize its real-time clock to a plant
distributed control system.  RTCnet
* Modbus is a trademark of Schneider Automation Inc.
compatible
Description   Low cost
alternative to a
The Flex500 control is packaged in an industrial hardened enclosure designed to be general purpose
bulkhead or panel mounted within a system control panel located in a plant control
room or next to the turbine/engine. Optionally, this controller can be purchased and PLC
applied with or without a front panel HMI (human machine interface). Panel-mount  Sulfur-resistant
models include an 8-inch (20 cm) graphical front panel screen and related keypad.
Bulkhead-mount models do not include a graphical display nor keypad and are conformal coating
designed to be mounted within an Ordinary Location or Zone-2 Hazardous Location  Certified for
environment.
Hazardous
Locations
 Woodward 03433 p.2

The control’s optional front panel serves as both an engineering station and operator control panel (OCP). This user-
friendly front panel allows plant operators to easily start/stop the turbine and enable/disable any control mode, as well
as enabling engineers to access and service the unit as required. Password security is used to protect access to all
unit operation and service modes. The optional controller’s 8-inch graphical display allows operators to view actual
and setpoint values from the same screen, simplifying operation.
Interface to the Flex500 control’s on-board input and output channels and communication ports is located on the
controller’s side and lower panels (see Figure 1). Un-pluggable terminal blocks allow for easy system installation,
troubleshooting, and replacement. Optionally users can increase the number and type of input and output signals
to/from the Flex500 controller by utilizing and connecting Woodward’s RTCnet and or LINKnet HT distributed I/O
modules to the Flex500’s CAN communication ports. Refer to Woodward product specification 03402 to better
understand the application of RTCnet and LINKnet HT distributed I/O modules.
The Flex500 control’s on-board and remote I/O are optimized for prime mover control. This controller’s 0.5 ms I/O
scan times, high accuracy, and software program synchronization make it ideal for use in controlling and protecting
critical high speed rotating equipment.

Figure 1. On-Board Inputs and Output Channels

Programming and Simulation 
The Flex500 control is programmed via Woodward’s popular GAP™ (Graphical Application Programming) language,
which has been qualified and specified by many rotating original equipment manufacturers (OEMs). This picture-to-
code graphical programming tool allows rotating machinery experts to easily and efficiently create complex control
algorithms without having to be software programming experts as well. GAP is a mature IEC1131-3 compliant
programming language and can be programmed using function blocks, ladder logic, and/or structured text.
One of the major advantages of Woodward’s GAP language is its many libraries of field-proven function blocks.
These blocks of functional algorithms have been used by turbine, compressor, and engine OEMs for years to quickly
and efficiently implement complex (or simple) control logic and or algorithms. Users can easily drag and drop
functions into the program, then connect them via drawn lines between the function blocks.
An essential part of any complex rotating control system is the capability to test and validate the related control logic
and algorithms before using it to operate/protect a real machine. Woodward’s NetSim™ simulation program links the
prime mover and package models (created in standard modeling packages—MATLAB®/Simulink® *, MATRIXX® **,
ACSL) to the created GAP software application program. With this simulation program, the created GAP-based
control code can be completely tested and validated within an office environment before field commissioning begins.
* MATLAB and Simulink are trademarks of The MathWorks, Inc.
** MATRIXX is a trademark of MATRIXX Software, Inc.

The performance of NetSim software is optimized to provide simulation results that correlate very tightly to actual
field results. Woodward’s worldwide organization has unequaled turbine and engine control expertise. To support its
OEM and packager customers, Woodward and our channel partners can supply software tools, or entire solutions, or
a variety of options in-between.
 Woodward 03433 p.3

Real‐Time Operating System (RTOS) 
The Flex500 controller’s structured scan rate and synchronized software-to-I/O architecture enforce fast,
deterministic, and completely repeatable dynamic behavior. Thorough and extensive FFT testing has proven that
screw-to-screw response times are exactly the same for every scan rate, regardless of what is happening elsewhere
in the controller. PLCs make use of a less rigid scan rate and synchronization structures that can introduce dynamic
instability as the processor becomes busy or code is added or removed.

Communications 
The Flex500 control can communicate directly with plant Distributed Control Systems and/or touch-screen operator
control panels through four Ethernet ports using Modbus TCP or OPC communication protocols, or via one serial
Modbus port. The included serial port supports both RS-232 or RS-485 communications and can be configured to
use ASCII or RTU Modbus protocols. Communications between the Flex500 control and a plant DCS can also be
performed through hardwired connections.

Control Specifications 
INPUTS
Power: LV models = 18–32 Vdc
HV models = 88–264 Vac & 90–150 Vdc
Speed: 2 Passive MPUs or 2 Active Proximity probes
(0.5–32 000 Hz)
Discrete Inputs: 20 configurable contact inputs
(optionally, additional inputs can be added via distributed I/O modules)
Analog Inputs: 8 Configurable 4–20 mA Inputs
(optionally, additional inputs can be added via distributed I/O modules)
OUTPUTS
Valve/Actuator Drivers: 2 actuator outputs, 4–20 mA or 20–200 mA
Discrete Outputs: 8 configurable relay outputs
(2 relays rated for 24 Vdc @ 5 A, 6 relays rated for 24 Vdc @ 2 A)
(optionally, additional outputs can be added via distributed I/O modules)
Analog Outputs: 6 programmable 4–20 mA outputs
(optionally, additional outputs can be added via distributed I/O modules)
COMMUNICATIONS
Ethernet: 4 ports (Modbus TCP or OPC protocols)
Serial: 1 Modbus port (ASCII or RTU) comm ports
(RS-232 or RS-485 compatible)
CAN: 4 ports (CANopen protocol)

Engineering Service Tools 
Control Assistant Service Tool—Windows-based trend viewing tool used to view high-speed datalog captures or
perform other useful utilities (program compare functions, etc.; see product specification 03201).
AppManager Service Tool—Windows-based tool used to upload and download GAP and GUI (graphical user
interface) based application programs, retrieving datalog files, and starting/stopping the programs
 Woodward 03433 p.4

Figure 2. Typical Flex500 Application—Bulkhead-Mount Model

Figure 3. Typical Flex500 Application—Panel-Mount Model

 Woodward 03433 p.5

Operating Conditions 
 –25 to +65 °C ambient air temperature range
 Humidity: Lloyd’s ENV2 test #1
 Dry Heat: Lloyd’s ENV3
 Salt Fog: US MIL-STD-810 method 509.2 procedure 1
 Shock: meets US MIL-STD-810C, method 516.2-1, procedure 1B
 Vibration: Lloyd’s ENV2 test #1

Pollution Resistance
 Particulate Pollution Resistance: IEC 664-1 Pollution Degree 2 (Normally only non-conductive pollution occurs.
 IEC 60068-2-60:1995 Part 2.60 Methods 1 and 4 (Flowing Mixed Gas Corrosion Test).
 Gaseous Pollution Resistance: Module conformal coating withstands NO2, CO2, SO2, and H2S gases.
 Will withstand levels typical of telecommunications and computer installations as defined by Battelle Labs Class
III (between IEC60721-3-3 classification 3C1 and 3C2, light industrial to urban industrial, heavy traffic).

Regulatory Compliance (PENDING) 
European Compliance for CE Marking:
These listings are limited to only those units bearing the CE Marking.
EMC Directive: 89/336/EEC COUNCIL DIRECTIVE
ATEX Directive: 94/9/EEC COUNCIL DIRECTIVE Zone 2, Category 3, Group II G EEx nA II T3 X
Other International Compliance:
GOST R: Certified for use in explosive atmospheres within the Russian Federation per GOST
R certificate POCC US. ГБ04.B01002 as 2ExnAIIT3X.
C-Tick (ACA/RSM): Declared to Australian Radiocommunications Act of 1992 and the New Zealand
Radiocommunications Act of 1989.
North American Compliance:
UL: UL Listed for Class I, Division 2, Groups A, B, C, and D. T3A at +60 °C Ambient
(rear enclosure provided) and T3B at +65 °C Ambient (rear enclosure omitted) for
use in Canada and the United States. UL File E156028.
Marine Compliance:
Lloyd’s Register (LR): Environmental Category ENV3 , Lloyd’s Register Type Approval Test Specification
Number 1, July, 2013.

Figure 4. Flex500 Dimensions (Do not use for construction)

 Woodward 03433 p.6

For more information contact:

PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com

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as authorized distributors and other authorized service and sales facilities
throughout the world. Complete address / phone / fax / email information for
all locations is available on our website.

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creating or becoming part of any Woodward contractual or warranty obligation unless
expressly stated in a written sales contract.
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